Drive Pinion Shaft Assembly: Assembly

Match the alignment marks, and install the coupling sleeve to the synchronizer hub and then install the shifting insert.
NOTE: Make sure that there is no large clearance at both sides of the shifting insert after assembly.

Fig 1: Identifying Shifting Insert, Synchronizer Hub And Coupling Sleeve
Courtesy of SUBARU OF AMERICA, INC.
Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring and 1st-2nd synchronizer hub onto driven shaft.
NOTE:
- Install the 1st-2nd synchronizer hub in proper direction.
- Align the protrusion of the outer baulk ring into the groove of the 1st-2nd synchronizer hub.
  
  Fig 2: Identifying 1st Driven Gear, Inner Baulk Ring, Synchro Cone, Outer Baulk Ring And 1st-2nd Synchronizer Hub
  Courtesy of SUBARU OF AMERICA, INC.
Install the 2nd driven gear bushing onto driven shaft using ST and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
- Attach a cloth to the end of the driven shaft to prevent damage.
- When press fitting, align the oil holes of the shaft and bushing.
ST 18654AA000 INSTALLER

Fig 3: Installing 2nd Driven Gear Bushing Onto Driven Shaft Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the 1st-2nd coupling sleeve.
NOTE:
- Install the 1st-2nd coupling sleeve in proper direction.
- Align the alignment marks of 1st-2nd coupling sleeve and the 1st-2nd synchronizer hub.
  
  Fig 4: Identifying 1st-2nd Coupling Sleeve
  Courtesy of SUBARU OF AMERICA, INC.
Install the 1st-2nd shifting insert.
NOTE: Press in the ball part to install.

Fig 5: Installing 1st-2nd Shifting Insert
Courtesy of SUBARU OF AMERICA, INC.
Install the outer baulk ring, synchro cone, inner baulk ring and 2nd driven gear to driven shaft.

Fig 6: Identifying 2nd Driven Gear, Inner Baulk Ring, Synchro Cone, Outer Baulk Ring And 1st-2nd Coupling Sleeve
Courtesy of SUBARU OF AMERICA, INC.
Install the key to the driven shaft.
Using the ST and a press, install the 3rd-4th driven gear.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
- Match the groove on the 3rd-4th driven gear to the key.
- Install the 3rd-4th driven gear in the proper direction.
ST 499277200 INSTALLER

Fig 7: Installing 3rd-4th Driven Gear Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the ball bearing onto driven shaft using ST and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Use a new ball bearing.

ST 499277200 INSTALLER

Fig 8: Installing Ball Bearing Onto Driven Shaft Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the 5th driven gear onto driven shaft using ST and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Install the 5th driven gear with the groove side facing the 6th driven gear.

ST 499277200 INSTALLER

Fig 9: Installing 5th Driven Gear Onto Driven Shaft Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the drive pinion spacer to the driven shaft.
Install the 6th driven gear onto driven shaft using ST and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Install with the stepped side on the end surface of the 6th driven gear facing the rear ball bearing side.

ST 499277200 INSTALLER

Fig 10: Installing 6th Driven Gear Onto Driven Shaft Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Install the ball bearing onto driven shaft using ST and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST 499277200 INSTALLER

Fig 11: Installing Ball Bearing Onto Driven Shaft Using Special Tool
Courtesy of SUBARU OF AMERICA, INC.
Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE: Use a new lock nut.

Tightening torque:

440 N.m (44.9 kgf-m, 324.5 ft-lb)

ST1 499987300 SOCKET WRENCH (50)

ST2 18680AA020 HOLDER

Fig 12: Removing/Installing Lock Nut Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Using a spring scale, check that starting load of the ball bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).

Fig 13: Checking Starting Load Of Ball Bearing Using Spring Scale
Courtesy of SUBARU OF AMERICA, INC.
Crimp the lock nut at two locations so that the dimension (B) becomes 39.1 mm (1.54 in) or less.
CAUTION: When crimping the lock nut, be careful not to crack it.

Fig 14: Identifying Lock Nut Crimping Dimension
Courtesy of SUBARU OF AMERICA, INC.
Install the roller bearing onto drive pinion.
NOTE:
- Use a new roller bearing.
- Install the knock pin hole of the roller bearing outer race, facing the rear side.
  
  Fig 15: Identifying Roller Bearing And Knock Pin Hole
  Courtesy of SUBARU OF AMERICA, INC.
Install the washer using ST1, ST2 and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 499277100 BUSHING 1-2 INSTALLER

ST2 499277200 INSTALLER

Fig 16: Installing Washer Using Special Tools
Courtesy of SUBARU OF AMERICA, INC.
Install the thrust bearing and needle bearing and install the driven shaft assembly.

Fig 17: Installing Driven Shaft Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.

Fig 18: Identifying Drive Pinion Collar, Needle Bearing, Adjusting Washer No. 1 And 2, Thrust Bearing And Differential Bevel Gear Sleeve
Courtesy of SUBARU OF AMERICA, INC.
Adjust the thrust bearing preload. Refer to THRUST BEARING PRELOAD .